Bobcat B900 B55Z11001 & Up 7446128 (08-21) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
Before Operation
Safe Operation Is The Operator’s Responsibility
Safe Operation Needs A Qualified Operator
Fire Prevention
PUBLICATIONS AND TRAINING RESOURCES
SERIAL NUMBER LOCATION
Backhoe Loader Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
MANUFACTURING LOCATIONS
BOBCAT BACKHOE LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
SERVICE SCHEDULE
Maintenance Intervals
Inspection Checkbook
SECURING THE STABILIZERS IN THE RAISED POSITION
Installing The Stabilizer Supports
TOWING THE MACHINE
Procedure
TRANSPORTING THE MACHINE ON A TRAILER
Loading And Unloading
Fastening
STOPPING THE ENGINE AND LEAVING THE MACHINE
BACKHOE LOADER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
OPERATOR CAB
Description
Cab Doors
Windshield Wiper
Side Windows
Rear Window
EMERGENCY EXIT
Side Windows
Rear Window
BACKHOE SWING / BOOM LOCK
Locking And Unlocking The Backhoe Boom / Swing Lock
APPROVED LIFT ARM SUPPORT DEVICE
Description
Installing The Approved Lift Arm Support Device
Removing The Approved Lift Arm Support Device
TIRE MAINTENANCE
Wheel Nuts
Rotating The Tires
Wheel Replacement
Mounting The Tires
Tire Pressure
ENGINE COVER
Opening And Closing The Engine Cover
GRILLE
Removal And Installation
ENGINE AIR CLEANER
Description
Cleaning The Outer Air Filter
Replacing The Air Filters
Cleaning The Air Pre-Cleaner
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Draining The Fuel Tank
Draining Water From The Fuel System
Removing Air From The Fuel System
Fuel Filters
Bleeding The Fuel System
ENGINE LUBRICATION SYSTEM
Engine Oil Chart
Checking And Adding Engine Oil
Removing And Replacing Oil And Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Removing And Replacing Coolant
HYDRAULIC SYSTEM
Hydraulic Fluid Chart
Checking And Adding Hydraulic Fluid
Removing And Replacing The Hydraulic Filters
Removing And Replacing The Hydraulic Fluid
REAR DRIVE AXLE
Cleaning The Rear Axle Breather
Differential
Reduction Gear
TRANSMISSION
Checking And Adding Oil
Removing And Replacing Oil
Replacing The Filter Element
ALTERNATOR AND FAN BELT
Belt Checking
Belt Adjustment
Belt Replacement
ATTACHMENT COUPLING SYSTEMS
Loader Attachment Coupling Inspection And Maintenance
Backhoe Attachment Coupling Inspection And Maintenance
BUCKET TEETH
Removal And Installation
LUBRICATING THE BACKHOE LOADER
Lubrication Locations
Lubricating The Stabilizer Wear Pads
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
Tightening Procedures
Test Point Location
General Maintenance Guidelines
SERVICE BRAKE SYSTEM
Description
Checking And Adding Brake Oil
Air Bleeding Procedure
Brake Pedal And Cylinders Removal And Installation
STEERING WHEEL AND CONSOLE
Removal And Installation
LOADER CONTROLS
Removal And Installation
BACKHOE AND STABILIZER CONTROLS
Removal And Installation
HYDRAULIC TANK
Removal And Installation
HYDRAULIC PUMP
Removal And Installation
Parts Identification
Disassembly And Assembly
Troubleshooting
STEERING VALVE
Removal And Installation
Parts Identification
LOADER CONTROL VALVE
Parts Identification
Testing And Adjusting
Removal And Installation
BACKHOE CONTROL VALVE
Parts Identification
Testing And Adjusting
Removal And Installation
RETURN LINE CHECK VALVE
Removal And Installation
Parts Identification
MAIN RELIEF VALVE
Testing
BACKHOE DISTRIBUTOR BLOCK
Removal And Installation
STEERING CYLINDER
Removal And Installation
Parts Identification
LOADER LIFT CYLINDERS
Removal And Installation
Parts Identification
Disassembly And Assembly
LOADER TILT CYLINDERS
Removal And Installation
Parts Identification
Disassembly And Assembly
BACKHOE SWING CYLINDERS
Removal And Installation
Parts Identification
Disassembly And Assembly
BACKHOE BOOM CYLINDER
Removal And Installation
Parts Identification
Disassembly And Assembly
BACKHOE ARM CYLINDER
Removal And Installation
Parts Identification
Disassembly And Assembly
BACKHOE BUCKET CYLINDER
Removal And Installation
Parts Identification
Disassembly And Assembly
STABILIZER CYLINDERS
Removal And Installation
Parts Identification
Disassembly And Assembly
SIDE SHIFT LOCK CYLINDERS
Removal And Installation
DRIVE SYSTEM
DRIVE SYSTEM INFORMATION
Troubleshooting Chart
GEAR SHIFT LEVER
Removal And Installation
PARKING BRAKE
Removal And Installation
ENGINE SPEED CONTROL LEVER
Removal And Installation
DRIVE SHAFT
Removal And Installation
Parts Identification
Disassembly And Assembly
TRANSMISSION
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
FRONT AXLE
Removal And Installation
Parts Identification
REAR DRIVE AXLE
Removal And Installation
Parts Identification
Disassembly And Assembly
Disassembly And Assembly
MAIN FRAME
FLOOR MAT
Removal And Installation
OPERATOR SEAT
Removal And Installation
FRONT INSTRUMENT PANEL
Removal And Installation
SIDE INSTRUMENT PANEL
Removal And Installation
FENDERS
Removal And Installation
REAR WINDOW
Removal And Installation
OPERATOR CAB
Removal And Installation
Cab Mount Removal And Installation
COUNTERWEIGHT
Removal And Installation
GRILLE FRAME
Removal And Installation
ENGINE COVER
Removal And Installation
FUEL TANK
Removal And Installation
LOADER
Removal And Installation
BACKHOE
Removal And Installation
SWING FRAME
Removal And Installation
STABILIZERS
Removal And Installation
Stabilizer Wear Pads Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting Chart
Description
Fuses And Relays Location
Fuses And Relays Identification
Pump Harness Connectors
Engine Harness Connectors
Fuses And Relays Harness Connectors
Cab Underside Harness Connectors
Cab Harness Connectors
Rear Harness Connectors
BATTERY
Battery Maintenance
Maintaining Battery Charge Level
Battery Service During Machine Storage
Battery Testing
Battery Charging
Using A Booster Battery (Jump Starting)
Removal And Installation
Adding Water To The Battery
Battery Disconnect Switch
ALTERNATOR
Belt Checking
Belt Adjustment
Belt Replacement
FUEL LEVEL SENDER
Testing
Removal And Installation
WINDSHIELD WIPER MOTOR
Removal And Installation
HORN
Removal And Installation
BACK-UP ALARM
Removal And Installation
LIGHTS
Removal And Installation
FRONT INSTRUMENTATION
Removal And Installation
SIDE INSTRUMENTATION
Removal And Installation
CAB FAN
Removal And Installation
RADIO
Removal And Installation
SPEAKERS
Removal And Installation
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Tightening Torques
Troubleshooting
Coating Liquid Gasket And Parts Assembly Procedure
Factors Which Determine When An Engine Overhaul Is Needed
CRANKCASE
Remove And Refit Cylinder Liners
Remove And Refit Timing Casing Cover And Back Plate
Remove And Refit Flywheel Housing
Install The Oil Seal In The Flywheel Housing
Remove And Refit Flywheel
Remove And Refit Flywheel
Install Ring Gear
Install Flywheel
Open Crankcase Ventilation (OCV)
CRANKSHAFT
Description
Remove And Refit Crankshaft
Renew Crankshaft Gear
Refit The Crankshaft Gear
Check Crankshaft Bend
Installation
Renew Crankshaft Main & Connecting Rod Bearing And Check Main & Connecting Rod Bearing Spread
Check And Grind Crankshaft
Remove And Refit Vibration Damper
PISTON AND CONNECTING RODS
Remove Piston Assembly
Dismantle And Assemble Piston And Connecting Rod
Remove Connecting Rod Bush
Installation Of Connecting Rod Bush
Inspect The Bushing Position After Installation
Check For Bend Of Connecting Rod
Install The Connecting Rod Bearing
Piston General
Remove Piston rings
Assemble Piston And Connecting Rod
Install Piston Rings
Installation
CYLINDER HEAD ASSEMBLY
Remove Cylinder Head
Grind Valves And Valve Seats
Refit The Valve Seat And To Check And Reface Valve Seat
Valve Seat Installation
Check The Valve Guide
Renew Valve Guide
Refit Valve And Valve Stem Seals
Check Valve Springs
Assemble The Cylinder Head
Spiral Tightening Sequence Indicating With Bolt Number
Assemble The Head Gasket
Cylinder Head Gasket Change Procedure
Assembly Procedure Of Cylinder Head Gasket
TIMING
Remove And Refit Rocker Levers
Remove, Refit And Check Push Rod And Tappets
Removal And Replacement Of Camshaft Bushes
Extraction
Installation
Install The Camshaft Gear On The Shaft
Refit The Camshaft
Remove And Refit Intermediate Timing Gear
Install The Idler Gear Shaft (Spindle)
Install The Idler Gear
Re-bush Intermediate Gear
Position Timing Gears For Valve Timing And FIP Timing
Timing Gear Backlash Checking
Fit Air Compressor (Wherever Applicable Otherwise Dummy Plate To Be Fitted)
Fuel Injection System
Schematic Layout Of Fuel Injection System
Remove Fuel Injection Pump
General Practices During Assembly & Rework
HP Pump Practices During Removal
Sensor Mounting Plate
Refit CR Pump Assembly
Pump Mounting Procedure
Remove Pump Drive Housing
Refit Pump Drive Housing
Mounting Of FIP On The Drive Housing Sub Assembly
Mounting Housing Subassembly To Engine
Mounting Pump Assembly On Engine
Fitment Of Common Rail (Injector Pipes Removed)
Removal Of Common Rail (Injector Pipes Removed)
Remove And Refit CRS injectors
Injector Parts Nomenclature
Safe Handling Of Injectors
Fitment Of High Pressure Pipes
Fitment Of Fuel Filter
Adjust the Valve Clearance
ENGINE LUBRICATION
Schematic Layout Of Oil Flow Diagram
Design And Operation
Remove And Refit Oil Pump
Overhaul Oil Pump
Refit Oil Pump
Overhaul Oil Cooler And Filter Assembly
Schematic Layout Of Oil Flow Diagram
Refit Oil Cooler
Install The Oil Strainer
Engine Piston Cooling Nozzle
Inspection Method For Piston Cooling Nozzle
During Complete / Semi-Overhauling Of The Engine, The Following Care To Be Taken In The Field
COOLING SYSTEM
General
Flush Cooling System
Baffle Plate
Thermostat
Test Thermostat
Install The Thermostat
Remove And Refit Water Pump
Overhaul Water Pump Dismantling
Remove And Refit Fan Belt To Adjust Fan Belt Tension
Tensioning Of Fan Belt
Belt Tension Procedure
Visually Inspect The Belt
EXHAUST GAS RECIRCULATION
Description
Parts Identification
EGR Cooler And EGR Valve
Remove Overhaul And Refit EGR Components
Remove EGR Coolant Pipes
Remove EGR Cooler
Dismantle EGR Cooler
Clean And Inspect
Assemble EGR Cooler
Refit EGR Cooler
Refit Exhaust Gas Pipes
Refit EGR Coolant Pipes
Remove And Refit Exhaust Manifold
Remove And Refit Intake Manifold
TURBOCHARGER
Description
Design and Operation
Benefits Of Turbo Charging
Enhancing Turbocharger Life
Parts Identification
Precautions To Be Taken For Turbocharger Installation
Best Practices
Troubleshooting
ELECTRONIC DIESEL CONTROL
Description
Parts Identification
Assembly Of EDC Engine Wiring Harness
EXHAUST PIPE
Removal And Installation
EXHAUST MUFFLER
Removal And Installation
RADIATOR
Removal And Installation
FAN
Removal And Installation
ENGINE
Removal And Installation
SPECIFICATIONS
BACKHOE LOADER SPECIFICATIONS
Machine Dimensions
Capacities
Loader Performance
Backhoe Performance
Controls
Engine
Hydraulic System
Electrical System
Drive System
Axles
Tires
Weights
Cab
Instrument Panel
Temperature Range
MACHINE TORQUE SPECIFICATIONS
Drive Line
Cab
Wheels
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
REGULAR MAINTENANCE ITEMS
Parts
Fluids, Lubricants And Fuel
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Mechanical Tools
Hydraulic Tools
Electrical Tools
ALPHABETICAL INDEX
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